1994 sundowner bow repair (with pics)

[CENLO]

I have removed the headliner and bow hatch (which was the sourse of the leak)

I zip cut a 3'x3' area (and saved the bottom skin)

Questions:

1) The boat is in my heated garage and I have a fan running 24hrs in the cuddy. I have most of the wet crap out.....there still is some (as per pics). I was wondering if I can use the CPES on the remaining areas and then replace the 3x3 core?

2) can I re-use the lower skin?

3) what is the best core replacement (as I will be walking on it) and the top is not flat? (something the can mold to the bow shape). I was planning on adding some 3/4" x 2" stripps across the bow and the fiberglassing them in to provide added support. (can they be gorilla glued in....or only fiberglassed?) what about a 3/4"x2" stripp of composite decking?

4) the roof area will be re-clothed after (so it doesnt have to be pretty)

5) I am fairly handy, but have never done fiberglass work before (epescially upside down)

The upper bow non-skid is in great shape.
If I knew the remaining damp core would not get worse I would be fine with leaving the remaining. The leak was from the unsealed hatch. I can leave it to dry for a while or ???

thanks in advance..........

 

[tpenfield]

Re: 1994 sundowner bow repair (with pics)

Working against gravity is going to require some creativity. You want to make sure you get all of the wet/rotten wood out. The penetrating epoxy will not really help you much with this type of repair.

If I were doing this work, I would . . .

"Press fit" the new wood core into the ceiling with epoxy or VE resin to secure it in place.

Then make a flexible board a bit larger than the repair area.

Use the flexible board to laminate the ceiling fiberglass/resin to the wood core . . . use a layer of 4 mil plastic (or similar) to keep the fiberglass from sticking to the flexible board.

Press fit the flexible board with the wetted fiberglass in place on the ceiling and let cure.

Probably a 2 person job.

You could possibly re-use the ceiling cut-out piece, but you will still have to apply fiberglass in an upside down manner to adhere the edges, making sure there is adequate strength, etc.

 

[jbcurt00]

Re: 1994 sundowner bow repair (with pics)

What did you & the dealer work out:

I bought the boat from a dealer and have a warranty. They asked me to get a quote to repair it.....or I can return the boat.

Can anyone recommend a good Northern or Central Michigan repair business? Any idea of cost (1500-2000)?

Ted has ya covered w/ the repair..

 

[CENLO]

Re: 1994 sundowner bow repair (with pics)

Working against gravity is going to require some creativity. You want to make sure you get all of the wet/rotten wood out. The penetrating epoxy will not really help you much with this type of repair.

If I were doing this work, I would . . .

"Press fit" the new wood core into the ceiling with epoxy or VE resin to secure it in place.

Then make a flexible board a bit larger than the repair area.

Use the flexible board to laminate the ceiling fiberglass/resin to the wood core . . . use a layer of 4 mil plastic (or similar) to keep the fiberglass from sticking to the flexible board.

Press fit the flexible board with the wetted fiberglass in place on the ceiling and let cure.

Probably a 2 person job.

You could possibly re-use the ceiling cut-out piece, but you will still have to apply fiberglass in an upside down manner to adhere the edges, making sure there is adequate strength, etc.

Can u recommend a good core product (flexible and strong) as the bow is not flat?

If I understand you correctly you are saying to use the flexible board to keep pressure on the core while it cures, and then step 2 is to use the board again with plastic on top and to lay the cloth on the plastic sheet and apply the resin and then lift the thing up to the ceing and brace till cured?

 

[tpenfield]

Re: 1994 sundowner bow repair (with pics)

I would use exterior grade plywood as the core . . . maybe 2 sheets in a laminated fashion if the core is fairly thick.. No need to use the 'flexible board' for the core as you can probably prop it up along the middle areas of the core and get it to stay in place and form to the contour of the deck.

Laminating the lower fiberglass layer is what will be tricky, and the 'flexible board' can hold the wetted glass in place while it cures and adheres to the core and perimeter edges.

Of course, if you could just flip the entire boat upside down, then gravity works to hold everything in place

 

[CENLO]

Re: 1994 sundowner bow repair (with pics)

can i use polyurethane glue for the new core

 

[tpenfield]

Re: 1994 sundowner bow repair (with pics)

You can, but it will probably cause problems with the resin, so don't . . .

Lots of threads here and elsewhere about folks using polyurethane (PL) adhesive and then having it peel up when the resin is applied. It needs to be really well cured, and who knows how long that will take :noidea: